1982 KZ250 Belt Drive to Chain Drive Conversion

Okay, so obviously this has been broached before, but after researching further, there is just no article out there with all of the information. I recently inherited a 1982 Kawasaki 250 CSR (apparently also known as a KZ 250). It has the standard belt drive, and as we all know, the belts you can no longer find. Here are my questions:
1) Even though they aren't listed, is there another belt that will fit?
2) If no belt is available, what is the part number of the chain drive conversion, or what parts do I need to make it work correctly?
3) If there is no kit and parts are hard to find, are there other options such as other rim/sprocket combinations from other motorcycles that will fit? (I have the 6-bolt rear pulley currently)
4) And lastly, can i still buy brake pads or would it be a good idea to go with discs if I am upgrading the rim anyways?
Thanks for your help and it is much appreciated. Can't wait to have this bike back on the road again

Jcochran wrote: ... I recently inherited a 1982 Kawasaki 250 CSR (apparently also known as a KZ 250). It has the standard belt drive, and as we all know, the belts you can no longer find....

59011-1011 Drive belt 125T

Presumably already inquired of:
www.partzilla.com/parts/detail/kawasaki/KP-59011-1011.html
www.speedsupplies.com/parts/kawasaki-59011-1011.htm
www.ronayers.com/BELTDRIVE125T-P4003217.aspx

Good Fortune!

Okay cool, now are there any part numbers for chain conversions? Those prices I'm finding are normal but holy jeez a chain is only $40 and will last longer!

well, I did it. I went to the motorcycle salvage yard and picked up a 82 305 wheel which has the Four-lug bolt pattern instead of the 6-lug like the 250. After some careful grinding and fitting, and a lot of filing, the 305 wheel fits perfectly. The brake hardware and torsion bar are the same spacing and style and just clipped together like the 250 wheel did. I also had to grind out the chain adjustment brackets since the 305 brackets aren't long enough since the frame on the 305 is different than the 250. The sprockets seem to line up well (I also got the front sprocket) but I have yet to put a chain on it. The 305 wheel will fit, but you have to be extremely careful when grinding to not get the whole too big or the axle will slide. Mine fits perfectly. Hopefully I can find a better front sprocket since the spline pattern isn't quite right and I don't want to goof that front output shaft up because you can't even buy those. Ill update again after I finish her up and maybe even post some pictures. Thanks guys!

Did Kawasaki ever build a chain drive KZ 250? If so, I bet those parts will bolt right on. That's what I did with my belt drive 750.

TexasKZ wrote: Did Kawasaki ever build a chain drive KZ 250? If so, I bet those parts will bolt right on. That's what I did with my belt drive 750.

Excellent point! The 1980 and 1981 KZ250 models were both chain drive. Here's the 1981 diagram. Ed

I had to get a custom offset front sprocket made when I converted my 82 305. Other than that I just had to remove the rear belt pulley and bolt on a rear sprocket from a 400 or 440 (I ferget which but can look it up).

do you know what the offset was specifically? I can run mine with a flat sprocket and know in just a few minutes whether I need an offset or not. Sprocket wear will also help me determine front sprocket offset. Thanks

Jcochran wrote: do you know what the offset was specifically? I can run mine with a flat sprocket and know in just a few minutes whether I need an offset or not. Sprocket wear will also help me determine front sprocket offset. Thanks

However achieved, it's critical that the sprockets be perfectly aligned.







Good Fortune!

okay cool. I got the 305 wheel to line right up with everything with the stock hardware (brake actuator, and torsion bar) and it all bolts up with the factory parts. Now I'm just looking for a front sprocket but I'm not sure about the offset, I need to get the belt guard off first to see. I have a laser so i plan on using that to check the alignment with the front sprocket

I ended up getting a beater sprocket or two from my local cycle recycle shop. The sprocket fits on the shaft and you almost have to tap it on with a rubber mallet to get it to work. Other than that it works out perfectly, with a laser, the sprockets line up very well and then chain clears everything in the case so no worries there. I didn't get time to shorten a chain before I came back to school this week but thats why they make weekends. Hopefully this weekend I will be able to get her lined up and back together for a quick test and tune ride.

well long story short the bike rides well. I got the chain mounted up and she runs just fine after a few adjustments. I also changed the bars. Im gonna start a new story on here detailing what I did for documentation purposes. Hope you all enjoy and thanks for the help!